FRONT SPRING AND / OR SHOCK ABSORBER REPLACEMENT

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Jack up Front End and Remove Wheel

Place jack stands beneath jack attachments.

Remove wheel.

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Remove link from steering rod

Remove nut and press out link using puller 5259.

Place a jack beneath control arm.

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Remove:

Anti-roll bar link from link.

Bolt from brake pipe bracket.

Detach pipes from clips.

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Loosen Shock Absorber Nut

Counterhold strut with 5037 and loosen nut a few turns with socket 5036.

NOTE: Use the wrench handle carefully. On certain models the ignition coil can be damaged if accidently hit.

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Mark position of upper mount Remove mount nuts and washers.

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Lower jack.

Pull down spring strut to free it from wing.

NOTE: Take care not to damage wing.

Hook spring strut onto anti-roll bar.

Use support hook 5045.

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Attach Spring Compressor Tool 5407 and Compress Spring

Place compressor tools opposite each other and with three free spring coils between the tool jaws.

Compress each side alternately.

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Remove Shock Absorber Nut

Use socket 5036 and holding tool 5037.

NOTE: For replacement of axial bearing only, remove washer, bearing, and axial bearing, then proceed to: Locate New Axial Ball

Bearing in Spring Plate section below.

Remove:

Washer.

Mount.

Axial bearing.

Shaped washer.

Spring seat.

Rubber spacer.

Bump stop.

Bellows.

Guide sleeve.

Spring.

NOTE: The spring seat and rubber spacer are one unit on 760 and 780 models 1988 and on.

NOTE: When replacing the spring only proceed to: Remove Spring Compressor Tool 5407 section below.

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Remove Shock Absorber Nut and Compress Absorber

Use hook spanner 5406, key 5303 and a wrench handle as a brace.

Install the new shock absorber and mounting nut.

Tighten nut using hook spanner 5406, key 5303 and a wrench handle as a brace.

NOTE: For replacement of shock absorber only, proceed to: Component Inspection section below.

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Remove Spring Compressor Tool 5407

Remove spring compressor tool by loosening alternately from the old spring.

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Compress the New Spring With Tool 5407

Place compressor tool 5607 opposite each other and with three free spring coils between the tool jaws.

Compress each side alternately.

Compress the spring until the length is approximately 275 mm (10.8 in) between ends.

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Component Inspection

Check:

mount.

axial bearing.

rubber spacer.

bellows, etc. for wear and damage.

Replace as needed.

NOTE: The picture shows only parts for the 740 model, not the 760 or 780 models from 1988.

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Install Spring

Pull the shock absorber piston rod out as far as possible.

Install spring on spring strut, bellows with guide sleeve, bump stop, rubber spacer, spring plate and the shaped washer

with taper downward.

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Locate New Axial Ball Bearing in Spring Plate

Ensure that the bearing seat is clean.

Locate axial bearing with the yellow half upwards.

Install mount, washer and nut.

Tighten nut but do not tighten completely.

Use socket 5036 and holder 5037.

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Remove Compression Tools

Loosen the jaws alternately.

Ensure that the spring ends are properly located in upper and lower plates.

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Guide spring strut into wheel housing

Remove suspension hook 5045 and raise jack.

Make sure anti-roll bar link is correctly seated.

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Install spring strut in wheel house tower according to previous markings.

Torque to 48 Nm (36 ft lb) .

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Tighten Upper Shock Absorber Nut

Use socket 5036 and holding tool 5037.

Torque to 70 Nm (52 ft lb) .

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Install:

Anti-roll bar to link.

Tighten nut so that distance between washers is 42 mm (1.65 in) .

Brake pipe bracket.

Brake pipe to clips.

NOTE: Ensure that pipes sit correctly in rubber grommets.

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Install link on steering rod Torque to 60 Nm (44 ft lb) .

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Install wheels

Torque to 85 Nm (63 ft lb) .